Rail joint and method of making the same



' June 14, 1938. H. R. LEE

RAIL JOINT AND METHOD OF MAKING THE SAME Filed Feb. 28, 1934 Z0 27 FFZ 7 323 INVENTOR HARRY R L ATTORNEY Patented June 14, 1938 UNITED STATES PATENT OFFICE RAIL JOINT AND METHOD OF THE s H Application February 28, 1934, Serial No. 713,278

18 Claims.

This invention relates to the art of reconditioning rail joints, and more especially it concerns a method of reforming Worn joint bars or plates to accurately fit the abutting ends of battered or worn rails.

The usual rail joint comprises a pair of joint bars arranged at the ends of two abutting aligned rails, the bars being disposed on opposite sides of the rails and bolted together through openings in the webs of the rails and the bars. When new, the upper fishing or bearing surfaces of the bars contact with the bottom surfaces of the rail heads, and the lower fishing surfaces of the bars contact with the top surfaces of the rail flanges, so that the bars fit accurately between the heads and flanges of the rails.

After a joint has been in use for some time, there develops progressive wear of the bars at their fishing surfaces, due to the constant pounding or battering of the rail ends at the joint by the wheels of trafiic moving upon the rails. The joints gradually become loose and the fishing surfaces of the bars become depressed at their mid-portions adjacent the worn ends of the rails.

Since the amount and shape of wear at the bearing surfaces of the bars and rails is not the same at all joints, it has long been known that the usual methods for rail joint repair, requiring removal of the bars from the joints and a subsequent crowning operation for building up the depressed portions of the bars, in addition to being relatively slow and costly, failed to provide at the respective rail joints the accurate fits required for effectively prolonging the active life of the joint members.

Among the important recent advances in the art of conditioning and repairing rail joints was the discovery that by reforming the joint bars while positioned at the rail joint the depressed areas of the bearing surfaces of the joint bars can be raised just enough to compensate for their V own wear and the wear of the bearing surfaces of the rails adjacent thereto. This is accomplished by forming one or more slots in each joint bar and then by suitable wedging means spreading the walls of said slot or slots vertically to press either or both of the upper and lower bearing surfaces of the bar into tight and conforming contact with the rail heads and flanges.

The above-mentioned method of rail joint conditioning depends upon driving the wedges by a series of sudden sharp blows applied at approximately right angles to the rail length. Since this usually is done manually with a trackmans hammer, the force applied is widely variable, as the (o1. 2ss 243) degree of impact is not uniform for successive blows. Furthermore, variations in the width of the slots produced in the bars or of the size or degree of bevel on the wedge members sometimes requires fitting of some of the wedge members to the slotted joint bars before driving the wedges into place.

The present invention is based upon the discovery that the important results attained in the above type of operation can be fully attained in a simple, easy manner, While eliminating in large measure the need for the said fitting of speciallysized parts. Moreover, standard interchangeable parts may in all cases be used as the rail barspreading agency.

Among the more important objects of the invention are the following: to provide in'novel manner for the reforming of joint bars while positioned at a rail joint; to provide in novel manner for reforming worn rail joint bars having therein one or more longitudinal slots and having at least one enlarged transverse aperture extending ,therethrough in a mid-portion of each of the said slots; to provide in novel manner for reforming a rail joint bar to produce a'crowned effect which compensates for its own wear and also the unevenwear in the rail bearing surfaces contacting therewith; and to provide a novel reformed rail joint bar having a crowned portion individually shaped under steady pressure to conform to the shape of the particular rail bearing surfaces contacting therewith.

Further objects and advantages of my invention will become apparent from the following description. The various features of novelty which characterize my invention are pointed out with particularity in the accompanying claims.

Referring to the drawing:

Fig. 1 is a side elevation of a worn rail joint having joint bars of angle bar form;

Fig. 2 is a longitudinal section taken through a worn rail joint bar embodying one form of my invention;

Fig. 3 is a perspective View of a Worn joint bar illustrating a feature of the invention;

Fig. 4 is a transverse sectional view through a rail joint illustrating one embodiment of my invention;

Fig. .5 is a transverse sectional view through a rail joint showing another embodiment of the invention;

Fig. 6 is a perspective view of one form of expansion member;

Fig. 7 is a perspective view of another form of expansion member and associated parts;

Figs. 8 and 9, respectively, are fragmentary views of rail joint bars illustrating still other modifications of the invention; and

Fig. 10 is a fragmentary front view of an elliptical expansion member and associated parts.

Referring to the drawing, there is shown a typical rail joint comprising a pair of joint bars I5, 16, having upper and lower fishing surfaces 24, 25. These bars may be of any well-known type, such as angle bars, disposed against the webs I1, 18, of two abutting rails I9, 20, and arranged on opposite sides of the rails. The bars are secured tightly together by bolts 2| passing through aligned apertures in the webs l1, l8, and apertures 22 in the bars l5, I6, the bolts having threaded ends to receive nuts 23.

When the rail joint is new, the upper and lower fishing surfaces 24, 25, of the bars 15, I6, fit the rails perfectly throughout the entire length of the bars. However, after the bars become slightly worn near the rail ends, the continual passage of traflic over the rails causes gradually increasing wear on the rail bearing surfaces 32, 33, that make occasional contact with the worn portions 30, 3|, of the bar. As progressive wear forms depressed areas, the bars no longer fill the spaces between the bearing surfaces of the rail heads and flanges.

The depressed worn areas of different joint bars may Vary in length and depth according to the amount of traffic that passes over different portions of track; and the said, areas will vary in shape according as the traffic is one-way, twoway with approximately the same amount in both directions, or two-way with the traffic in one direction exceeding the trafiic in the opposite direction.

In accordance with one form of the present invention the joint bars I5, I6, may be reformed while positioned at the rail joint against the rails 19, 20. When this is done the rail heads 26, 21, and rail flanges 23, 29, serve as cooperating die elements to reshape the bearing surfaces of the joint bars.

In the practice of the invention, one or more relatively narrow longitudinal slots 35 are out or otherwise formed in the mid-portions of the bars l5, l6 adjacent the depressed worn portions 30, 3|. Each slot is located sufiiciently close to the bearing surface to be reshaped that the application of an expanding force within the slot will cause the metal of the bar to spring or flow and thus to fill the depressed areas formed by wear on the bearing surfaces of the bars and the rails, to provide a satisfactory reformed rail joint.

In the form of the invention illustrated in Figs. 2 to 5, a single long narrow slot 35 is shown as joining the two track-bolt apertures 22 nearest the joint between abutting rails. However, the slot may be shorter, so as to terminate at one or both ends in solid metal of the rail web, provided always that the slot has such length and position that the expanding force within it will cause a springing or flowing movement of the surrounding metal of the bar suflicient to fill the worn depressed areas in the fishing surfaces.

For applying force to spread the joint bars vertically for filling the spaces between the bars and rails due to wear, a large transverse aperture 31, preferably circular in cross section and at least 1 inches in diameter, is drilledor otherwise formed in each of the joint bars l5, H5, at about midlength of the slot 35. It is advantageous to position this aperture approximately midway of the height of the slot 35. The walls forming the apertures 31 may be tapered, as shown in Fig. 4.

A pair of cooperating, channel-shaped, internally-threaded expansion members or segments 39 of hardened metal or alloy, each having a longitudinally-tapered outer surface 4|, are adapted to be removably mounted within the aperture 31 with a portion projecting outwardly therefrom. The outer surfaces of the respective segments 39 adjacent the margins of the slot 35 preferably are flattened in parallel planes normal to a horizontal plane through the said slot to provide lips 42, 42. The pair of members 39, 39 are inserted into the circular apertures 3'! with these flattened portions vertically disposed. Then when the members 39, 39 are urged apart under the action of a bolt 43, all or the major portion of the pressure is transmitted vertically upward and downward toward the worn fishing surfaces of the joint bar. Moreover, it will be seen that the area of that portion of the bar at the aperture 3'! that is acted upon by the downwardly-directed forces, applied through the segments 39, is approximately the same as the area of the portion of the bar at the aperture which is acted upon by upwardly-directed forces.

The curved portion of the outer surface of each of the pair of separate cooperating channelshaped expansion members 39 preferably subtends an angle of about (see Fig. 6). The members are adapted to be placed in juxtaposition with their lips closely adjacent or in contact.

The inner surfaces of the members 39, 39, are threaded to accommodate a heavy or armored threaded bolt or a tapered cap screw 43 of hardened metal, preferably of around 1% inches to 1% inches or more in diameter. The construction of these parts is such that the threadwise movement of the bolt into the members 39 forces the segments apart and presses them against the inner wall of the aperture 31.

These segments are placed with the curved portions of their outer surfacesrespectively below and above the bolt. When the progressively increasing pressure developed as the bolt advances in the members 39 has reached a suitable magnitude, slight movement of the metal of the joint bars occurs in the direction of the upper and lower bearing surfaces of the bars to effect the desired spreading action.

This spreading action at the selected areas of a joint bar may be facilitated, and the fit of the bar to the bearing surfaces of the rail may be improved, by heating those portions of the joint bar in which plastic flow of the metal in response to the pressure is desired. Such heating may be performed either before or during the tightening of the screw or bolt 43. This can be accomplished, for instance, through raising selected areas of the joint bar to a dull red near the bearing surfaces to be corrected; and for this the oxy-acetylene flame is preferred.

Where heating is to be utilized, the expansion members and the cooperating bolt or other spreading member preferably are made of airhardening steel or other air-hardening alloy, such as the alloy steel containing chromium, manganese and silicon, commercially known as Cromansil. Thus the subsequent air cooling will restore much of the original strength and hardness of the metal.

' Although for purposes of illustration I have shown the slot or slots 35 to be long, narrow, and of uniform width, such construction is not essential to the practice of the invention. However,

the longer this slot, the more readily can the metal between the slot and the rail bearing surface be forced into place for reforming the joint. The slot or slots 35 and the transverse aperture or apertures 31 may, if desired, be formed without removing the bars l5, I6, from the rails, by means of a cutting torch or other well-known means.

After the slots 35 and apertures 3'! have been formed in each bar [5, [6, the expansion members 39 are placed in the apertures of the respective bars and these segments are forced apart by screwing the bolt 43 into the same to force either or both the upper andlower surfaces of each bar into contact with the adjacent surfaces of the rail head and/or flange.

After restoring the joint, the bolt 43 may be locked in position in the members 39, 39 in suitable manner, if desired, as for example, by pins extending through the shaft of the bolt and engaging the walls of the members 39 or of the bar.

The pitch and shape of thread and the diameter of the bolt most effective for practicing the invention will naturally depend on such factors as the cross-sections of metal to be deformed, the thickness of the bar at the apertures receiving the expansion members, and the number, design, and locations of the expansion members.

Fig. 5 illustrates another modification of the invention in accordance with which a transverse aperture 45 is drilled or otherwise formed in the rail web or webs in or near the junction of the rails. This aperture is aligned with the apertures 3'! in the webs of the joint bars l5, it. A large bolt 47 provided with cooperating nut 49 of large threaded bearing surface is adapted to extend through the apertures 3'1, 31, and 45 in the bars and rail web respectively, with its ends projecting therefrom.

Collars or tubular bearing members 5|, each having a tapered outer surface 53 of frusto-conical shape and having an inner passage adapted freely to accommodate the bolt 41, are positioned within the apertures 37, 3'! in the joint bars. The bolt 4'! extends through these collars in the manner illustrated in Fig. 5. By turning the nut on the bolt 41 the two collars can be forced toward each other to the extent necessary to spread the upper and lower fishing areas of each bar to prop erly contact them with the adjacent portions of the rail head and rail flange respectively. Stud bolts or other equivalent means for the purpose may be substituted for the bolt 41.

Fig. '7 illustrates a modification of the invention according to which the midportion of the outer surface of each tapered expansion member is substantially fiat as indicated at 44. The similarly shaped polygonal aperture 31 may be formed by means of an oxy-acetylene torch or in other suitable manner. It preferably is of less width than the expansion members 44.

Fig. 8 illustrates a modification of the invention especially adapted for use where for any reason the bearing surfaces between the rail and the joint bars have been worn irregularly. In this form of the invention, two or more longitudinally-spaced transverse apertures 31, 3'! are provided in the joint bars l5, IS, in the manner previously described, each having its axis at least approximately intersecting the line of the longitudinal axis of slot 35.

These apertures may be of the same or different sizes and shapes. Preferably, where two apertures 31, 31 are used, they are located respectively near and at points equidistant from the rail ends and on opposite sides of the abutting joint. The expansion members previously described are positioned within these apertures; and each may then be adjusted to refit the joint bar to the rail bearing surfaces with the application of a minimum of force to those portions of the rail and bar where the least refitting is required.

Instead of utilizing only one longitudinal slot 35, two such slots may be used, respectively placed adjacent the upper and lower fishing surfaces of the joint bars l5, Hi. This modification is illustrated in Fig. 9; and it is of especial utility in reforming the heavier rails, such as pound to 136 pound rails and upward. By this construction it is possible to place the slots 35 sufliciently close to the fishing surfaces of the joint bars of heavy rails that the spreading force developed readily produces the necessary springing or flowing movement of the portion of the bar adjacent the fishing surfaces to complete the reforming operation.

It is to be understood that the apertures 31 together with the expansion members 39, or the collars 5!, may be elliptical, square, rectangular, or may have other conformations, provided they are tapered in one direction longitudinally of the associated bolt or force-transmitting member and can function in the general manner described. Fig. 10 illustrates a form of construction in which is provided a smooth-bored aperture 37" that is generally elliptical in cross-section, with its major axis preferably disposed longitudinally of the rail. The bolt 43 is replaced in this construction by an unthreaded bar 46 of hardened metal, of generally elliptical cross-section, having its major transverse axis slightly longer than the minor transverse axis of the aperture 31". By rotating the bar Within the aperture 31 a steady vertically-directed spreading pressure may be exerted upon the walls of the joint bar at the slot. When the reforming process is completed, the portion of the bar within the aperture can be spot welded or otherwise secured in place. One or more such elliptical expansion members may be employed.

By the practice of the present invention, rail joints may be reconditioned at regular intervals accurately and readily, using standard track tools and wrenches for the purpose. There is no necessity for sledging or otherwise suddenlyand severely impacting the rails and the adjacent joint bars.

1 By developing the spreading force at the apertures 31, generally midway of the length of the joint and of the slot 35, and by distributing the force from that point, the'resultant movement of the metal is greatest at the rail ends, where the,

greatest wear is usually encountered. Because of the ease with which the trackman can adjust the rail joints, simple periodic tightening upon the bolts to increase the steady pressure exerted by the expansion members will maintain the joints in perfect condition with a minimum of labor and expense.

The amount of wear on the bearing surfaces of rails and joint bars is actually very small. Hence a slight corrective movement of the metal of the joint bar at the depressed portion is sufficient,- when periodically produced with proper frequency,-to maintain a satisfactorily tight rail joint. On the other hand, as the depths of the depressed areas of the joint bar and rail endsbecome greater with the constant batter of the traffic on the rails, the rateofincreasein'depth of this depressed area is accelerated, and the rails and joint bars rapidly wear away.

Where it is desirable in reforming the joint to change the contour of but one fishing surface, the slot 35 may be out near the depressed worn area.

Instead of slotting standard rail joint bars in the manner described after they are worn, the slotted and/or apertured structure can be built into the bars at the mill. When new slotted and apertured bars are used, metal blocks of suitable shape may be inserted into and fill the slots and/or apertures and be secured to the bars in any suitable manner, for example, by spot welding. When the joints become worn, the metal block may be removed and the expansible member or members then placed in position within the apertures.

In certain instances where it is desired to reform joint bars, utilizing the rails as die elements,--after the depressed worn area of the joint bar has been forced into contact with the adjacent worn bearing surfaces of the rails under pressure from the expansion members,-the portion of the slot not occupied by the latter may be built up with welding metal to provide a rigid rail joint.

According to my invention, the forces applied within the body of the joint bar to reform it are steadily and uniformly applied in vertical planes extending longitudinally of the joint bar, without subjecting the bar to severe impacts or to the sudden application of a force principally directed transversely of the bar.

It will be apparent to those skilled in the art that types of rail joint bars otherthan the angle bar type illustrated may be employed. The invention is susceptible of modification within the scope of the appended claims.

I claim:

1. A method of crowning a fishing surface of a rail joint bar, which comprises longitudinally slotting said bar intermediate its ends, enlarging the slot at a midportion thereof to provide a curved bearing surface of relatively large area free from abrupt changes in cross-section, slowly expanding the slot at a regulated rate by forces applied to the said bearing surface approximately uniformly across the entire thickness of the bar, thereby forming a crowned area in said fishing surface, and locking the slot in its expanded condition.

2. A method of crowning a fishing surface of a longitudinally-slotted joint bar, which comprises forming an enlarged tapered aperture in the bar in the line of the said slot, gradually spreading the walls of the slot by force uniformly and gradually applied thereto at the said aperture and approximately uniformly across the entire thickness of the bar to raise a midportion of the said fishing surface, and releasably locking the said slot in its widened condition.

3. A method of crowning a fishing surface of a longitudinally-slotted joint bar, which comprises forming an enlarged polygonal aperture free from abrupt changes in cross-section in the bar in the midportion of the line of the slot, and applying a spreading pressure to the bar across the entire width thereof at the aperture and directed mainly toward a fishing surface to spread the said slot so as laterally to expand the portion of the bar opposite the slot, and releasably locking said slot in its spread condition.

4. A method of crowning a fishing surface of a longitudinally-slotted joint bar, which comprises forming an enlarged aperture in the bar in the midportion of the line of the slot, applying a steady spreading pressure to the bar at the said aperture uniformly across the entire thickness of the bar so as laterally to spread the portion of the bar adjacent the aperture, and releasably locking said slot in its spread condition by a welding operation.

5. A method of crowning a fishing surface of a bar having a comparatively long and narrow longitudinal slot therein, which comprises forming in the bar adjacent the said fishing surface an enlarged transverse aperture limited in part by tapered walls extending through the bar, the said aperture having a portion thereof in the longitudinal axis of the said slot, and forcing apart portions of the bar at the aperture and on opposite sides of the slot under relatively steady pressure produced by a force having its principal component applied at the aperture and directed toward a fishing surface of the bar across the entire thickness of the bar to change the contour of the said fishing surface and form a crowned area therein opposite said slot.

6. A reconditioned rail joint comprising opposed rail ends and a joint bar connecting the same having a crowned area in at least one fishing surface thereof, a longitudinal slot in said bar opposite said crowned area, said slot being adapted to be spread to produce such crowned area, a sectional tapered member adapted to extend into said slot, and rotatable means for regulatably spreading the sections of the said tapered member and the slot and for maintaining the slot in spread condition.

7. A reconditioned rail joint comprising opposed rail ends and a joint bar connecting the same having a crowned area in at least one fishing surface thereof, a longitudinal slot in the bar opposite the said crowned area, and at least one seetional transversely expansible member in said slot and cooperating therewith to produce and maintain said crowned area.

8. A rail joint comprising opposed rail ends and joint bars connecting the same, each bar having a crowned area in at least one fishing surface thereof, a longitudinal slot in each bar opposite the crowned area, at least one sectional member extending transversely through the joint bars and slot and expansible radially of and within the plane of each joint bar and adapted to produce and maintain the said crowned area, and rotatable means for expanding the said expansible member.

9. A rail joint bar having upper and. lower fishing surfaces with crowned areas, a narrow longitudinal slot in said bar adjacent said crowned areas and having at least one enlarged portion, a tapered segmental expansion member extending within the said enlarged portion and adapted to engage the bar only adjacent the said crowned areas in the upper and lower fishing surfaces, and rotatable means cooperating with the said member for maintaining the slot in widened condition adjacent the said enlarged portion to produce the said crowned areas.

10. A reconditioned rail joint comprising opposed rail ends, a joint bar connecting the same and having a crowned area in at least one fishing surface thereof, a longitudinal slot in the bar opposite the said crowned area, the said slot having at least one enlarged portion of generally elliptical cross-section, the same being free from abrupt changes in transverse cross-section, and being adapted to be spread to produce the said crowned area, and rotatable means of generally elliptical cross-section and free from abrupt changes in such cross-section, adapted to extend into the said enlarged portion for regulating the extent of the spreading action and for maintaining the slot in spread condition.

11. A rail joint comprising opposed rail ends and joint bars connecting the same, each bar having a crowned area in at least one fishing surface thereof, a longitudinal slot in each bar midway of its length, a relatively large transverse aperture extending through the respective bars and rail ends and intersecting the lines of the said slots, expansion means extending within the aperture and comprising a pair of cooperating members each having portions of its outer surface shaped to fit the Wall of the aperture and having other portions out of contact with the said walls, and a member for actuating the expansion means.

12. A method of crowning a fishing surface of a longitudinally-slotted joint bar having an enlarged aperture therein in the line of the slot, which comprises heating at least the fishing surface to be crowned, gradually spreading the walls of the slot by the steady application thereto of forces applied to the bar at the said aperture, thereby raising a midportion of the said fishing surface to form a crowned area, and welding the bar to maintain the crowned fishing surface in its new position.

13. A method of crowning a fishing surface of a longitudinally-slotted joint bar, which comprises forming a large tapered aperture in the bar in the line of the said slot, gradually spreading the walls of the slot by forces applied thereto at the said aperture to raise a midportion of the said fishing surface, while applying heat to that portion of the fishing surface adjacent the said aperture, and releasably locking the said slot in its widened condition.

14. A reconditioned rail joint, comprising opposed rail ends and a joint bar connecting the same having a crowned area in at least one fishing surface thereof, a longitudinal slot in the bar opposite the said crowned area, and at least one sectional expandible member of air-hardening ferrous metal alloy in said slot, and cooperating therewith to produce and maintain said crowned area.

15. A reconditioned rail joint comprising opposed rail ends, a joint bar connecting the same having a crowned area in at least one fishing surface thereof, a longitudinal slot in the bar opposite the said crowned area, and means disposed in said slot and expansible transversely of the bar and cooperating with the walls of the slot to produce and maintain said crowned area.

16. A reconditioned rail joint comprising opposed rail ends, a joint bar connecting the same having a crowned area in at least one fishing surface thereof, a longitudinal slot in the bar opposite the said crowned area, and means including a threaded member disposed in said slot and having parts movable vertically within the vertical plane of the bar and cooperating with the Walls of the slot to produce and maintain said crowned area.

17. A rail joint comprising opposed rail ends and joint bars connecting the same, each bar having a crowned area in at least one fishing surface, a longitudinal slot in each bar opposite the said crowned area, and at least one pair of internallythreaded segmental expansion members extending transversely of and through a corresponding one of the bars but not through the rails, and

threaded members adapted respectively to cooperate with a corresponding pair of the expansion members to cause a spreading movement of the latter.

18. A rail joint bar having upper and lower fishing surfaces, parallel narrow longitudinal slots in the bar respectively adjacent the said surfaces, each of the said slots having at least one enlarged midportion, tapered segmental expansion members respectively extending within each of the said enlarged portions, and means cooperating with the respective segments of the said members for spreading apart the latter and for maintaining the slots in widened condition.

HARRY R. LEE. 

